Welding is complete on the largest piece of the core stage that will provide the fuel for the first flight of NASA's new rocket, the Space Launch System, with the Orion spacecraft in 2018. The core stage liquid hydrogen tank has completed welding on the Vertical Assembly Center at NASA's Michoud Assembly Facility in New Orleans. Credit: NASA/MAF/Steven Seipel
Welding is complete on the largest piece of the core stage that will provide the fuel for the first flight of NASA’s new rocket, the Space Launch System, with the Orion spacecraft in 2018. The core stage liquid hydrogen tank has completed welding on the Vertical Assembly Center at NASA’s Michoud Assembly Facility in New Orleans. Credit: NASA/MAF/Steven Seipel
The first of the massive fuel tanks that will fly on the maiden launch of NASA’s SLS mega rocket in late 2018 has completed welding at the agency’s rocket manufacturing facility in New Orleans – marking a giant step forward for NASA’s goal of sending astronauts on a ‘Journey to Mars’ in the 2030s.
Welding is nearly complete on the liquid hydrogen tank will provide the fuel for the first flight of NASA’s new rocket, the Space Launch System, with the Orion spacecraft in 2018. The tank has now has now completed welding on the Vertical Assembly Center at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
This flight version of the hydrogen tank is the largest of the two fuel tanks making up the SLS core stage – the other being the liquid oxygen tank (LOX).
In fact the 130 foot tall hydrogen tank is the biggest cryogenic tank ever built for flight.
“Standing more than 130 feet tall, the liquid hydrogen tank is the largest cryogenic fuel tank for a rocket in the world,” according to NASA.
And it is truly huge – measuring also 27.6 feet (8.4 m) in diameter.
The liquid hydrogen tank qualification test article for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally after final welding was completed at NASA’s Michoud Assembly Facility in New Orleans in July 2016. Credit: Ken Kremer/kenkremer.com
The precursor qualification tank was constructed to prove out all the manufacturing techniques and welding tools being utilized at Michoud.
The first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
SLS is the most powerful booster the world has even seen and one day soon will propel NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!
NASA’s agency wide goal is to send humans to Mars by the 2030s with SLS and Orion.
The LH2 and LOX tanks sit on top of one another inside the SLS outer skin. Together the hold over 733,000 gallons of propellant.
The SLS core stage – or first stage – is mostly comprised of the liquid hydrogen and liquid oxygen cryogenic fuel storage tanks which store the rocket propellants at super chilled temperatures. Boeing is the prime contractor for the SLS core stage.
The SLS core stage stands some 212 feet tall.
The SLS core stage is comprised of five major structures: the forward skirt, the liquid oxygen tank (LOX), the intertank, the liquid hydrogen tank (LH2) and the engine section.
The LH2 and LOX tanks feed the cryogenic propellants into the first stage engine propulsion section which is powered by a quartet of RS-25 engines – modified space shuttle main engines (SSMEs) – and a pair of enhanced five segment solid rocket boosters (SRBs) also derived from the shuttles four segment boosters.
NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com
The vehicle’s four RS-25 engines will produce a total of 2 million pounds of thrust.
The tanks are assembled by joining previously manufactured dome, ring and barrel components together in the Vertical Assembly Center by a process known as friction stir welding. The rings connect and provide stiffness between the domes and barrels.
The LH2 tank is the largest major part of the SLS core stage. It holds 537,000 gallons of super chilled liquid hydrogen. It is comprised of 5 barrels, 2 domes, and 2 rings.
The LOX tank holds 196,000 pounds of liquid oxygen. It is assembled from 2 barrels, 2 domes, and 2 rings and measures over 50 feet long.
The maiden test flight of the SLS/Orion is targeted for no later than November 2018 and will be configured in its initial 70-metric-ton (77-ton) Block 1 configuration with a liftoff thrust of 8.4 million pounds – more powerful than NASA’s Saturn V moon landing rocket.
Although the SLS-1 flight in 2018 will be uncrewed, NASA plans to launch astronauts on the SLS-2/EM-2 mission slated for the 2021 to 2023 timeframe.
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
The newly assembled first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
A scene from ‘Destination Mars’ of Buzz Aldrin and NASA’s Curiosity Mars rover with the Gale crater rim in the distance. The new, limited time interactive exhibit is now showing at the Kennedy Space Center visitor complex in Florida through Jan 1, 2017. Credit: NASA/JPL/Microsoft
A scene from ‘Destination Mars’ of Buzz Aldrin and NASA’s Curiosity Mars rover with the Gale crater rim in the distance. The new, limited time interactive exhibit is now showing at the Kennedy Space Center visitor complex in Florida through Jan 1, 2017. Credit: NASA/JPL/Microsoft
KENNEDY SPACE CENTER VISITOR COMPLEX, FL- Think a Holodeck adventure on Star Trek guided by real life Apollo 11 moonwalker Buzz Aldrin and you’ll get a really good idea of what’s in store for you as you explore the surface of Mars like never before in the immersive new ‘Destination Mars’ interactive holographic exhibit opening to the public today, Monday, Sept.19, at the Kennedy Space Center visitor complex in Florida.
The new Red Planet exhibit was formally opened for business during a very special ribbon cutting ceremony featuring Buzz Aldrin as the star attraction – deftly maneuvering the huge ceremonial scissors during an in depth media preview and briefing on Sunday, Sept. 18, 2016, including Universe Today.
The fabulous new ‘Destination Mars’ limited engagement exhibit magically transports you to the surface of the Red Planet via Microsoft HoloLens technology.
It literally allows you to ‘Walk on Mars’ using real imagery taken by NASA’s Mars Curiosity rover and explore the alien terrain, just like real life scientists on a geology research expedition.
A ceremonial ribbon is cut for the opening of new “Destination: Mars” experience at the Kennedy Space Center visitor complex in Florida during media preview on Sept. 18, 2016. From the left are Therrin Protze, chief operating officer of the visitor complex; center director Bob Cabana; Apollo 11 astronaut Buzz Aldrin; Kudo Tsunoda of Microsoft; and Jeff Norris of NASA’s Jet Propulsion Laboratory in Pasadena, California. Credit: Ken Kremer/kenkremer.com
“Technology like HoloLens leads us once again toward exploration,” Aldrin said during the Sept. 18 media preview. “It’s my hope that experiences like “Destination: Mars” will continue to inspire us to explore.”
Destination Mars was jointly developed by NASA’s Jet Propulsion Laboratory – which manages the Curiosity rover mission for NASA – and Microsoft HoloLens.
A ceremonial ribbon is cut for the opening of new “Destination: Mars” experience at the Kennedy Space Center visitor complex in Florida during media preview on Sept. 18, 2016. From the left are Therrin Protze, chief operating officer of the visitor complex; center director Bob Cabana; Apollo 11 astronaut Buzz Aldrin; Kudo Tsunoda of Microsoft; and Jeff Norris of NASA’s Jet Propulsion Laboratory in Pasadena, California. Credit: Dawn Taylor Leek
Buzz was ably assisted at the grand ribbon cutting ceremony by Bob Cabana, former shuttle commander and current Kennedy Space Center Director, Therrin Protze, chief operating officer of the visitor complex, Kudo Tsunoda of Microsoft, and Jeff Norris of NASA’s Jet Propulsion Laboratory in Pasadena, California.
The experience is housed in a pop-up theater that only runs for the next three and a half months, until New Years Day, January 1, 2017.
Before entering the theater, you will be fitted with specially adjusted HoloLens headsets individually tailored to your eyes.
The entire ‘Destination Mars’ experience only lasts barely 8 minutes.
So, if you are lucky enough to get a ticket inside you’ll need to take advantage of every precious second to scan around from left and right and back, and top to bottom. Be sure to check out Mount Sharp and the rim of Gale Crater.
You’ll even be able to find a real drill hole that Curiosity bored into the Red Planet at Yellowknife Bay about six months after the nailbiting landing in August 2012.
During your experience you will be guided by Buzz and Curiosity rover driver Erisa Hines of JPL. They will lead you to areas of Mars where the science team has made many breakthrough discoveries such as that liquid water once flowed on the floor of Curiosity’s Gale Crater landing site.
Curiosity rover driver Erisa Hines and Jeff Norris of NASA’s Jet Propulsion Laboratory at the grand opening for Destination Mars at the Kennedy Space Center visitor complex in Florida on Sept. 18, 2016. Credit Julian Leek
The scenes come to life based on imagery combining the Mastcam color cameras and the black and white navcam cameras, Jeff Norris of NASA’s Jet Propulsion Laboratory in Pasadena, California, told Universe Today in an interview.
Among the surface features visited is Yellowknife Bay where Curiosity conducted the first interplanetary drilling and sampling on another planet in our Solar System. The sample were subsequently fed to and analyzed by the pair of miniaturized chemistry labs – SAM and CheMin – inside the rovers belly.
They also guide viewers to “a tantalizing glimpse of a future Martian colony.”
“The technology that accomplishes this is called “mixed reality,” where virtual elements are merged with the user’s actual environment, creating a world in which real and virtual objects can interact, “ according to a NASA description.
“The public experience developed out of a JPL-designed tool called OnSight. Using the HoloLens headset, scientists across the world can explore geographic features on Mars and even plan future routes for the Curiosity rover.”
Curiosity is currently exploring the spectacular looking buttes in the Murray Buttes region in lower Mount Sharp. Read my recent update here.
A scene from ‘Destination Mars’ of Erisa Hines and NASA’s Curiosity Mars rover with Mount Sharp Gale crater rim in the distance. The new, limited time interactive exhibit is now showing at the Kennedy Space Center visitor complex in Florida through Jan 1, 2017. Credit: NASA/JPL/Microsoft
Be sure to pay attention or your discovery walk on Mars will be over before you know it. Personally, as a Mars lover and Mars mosaic maker I was thrilled by the 3 D reality and I was ready for more.
Curiosity accomplished Historic 1st drilling into Martian rock at John Klein outcrop on Feb 8, 2013 (Sol 182) and discovered a habitable zone, shown in this context mosaic view of the Yellowknife Bay basin taken on Jan. 26 (Sol 169). The robotic arm is pressing down on the surface at John Klein outcrop of veined hydrated minerals – dramatically back dropped with her ultimate destination; Mount Sharp. Credit: NASA/JPL-Caltech/Ken Kremer-kenkremer.com/Marco Di Lorenzo
This limited availability, timed experience is available on a first-come, first-served basis. Reservations must be made the day of your visite at the Destination: Mars reservation counter, says the KSC Visitor Complex (KSCVC).
You can get more information or book a visit to Kennedy Space Center Visitor Complex, by clicking on the website link:
Be sure to visit this spectacular holographic exhibit before it closes on New Year’s Day 2017 because it is only showing at KSCVC.
There are no plans to book it at other venues, Norris told me.
Apollo 11 moonwalker Buzz Aldrin describes newly opened ‘Destination Mars’ holographic experience during media preview at the Kennedy Space Center visitor complex in Florida on Sept. 18, 2016. Credit: Ken Kremer/kenkremer.com
As of today, Sol 1465, September 19, 2016, Curiosity has driven over 7.9 miles (12.7 kilometers) since its August 2012 landing inside Gale Crater, and taken over 354,000 amazing images.
Apollo 11 moonwalker Buzz Aldrin during media preview of newly opened ‘Destination Mars’ holographic experience at the Kennedy Space Center visitor complex in Florida on Sept. 18, 2016. Credit Julian Leek
Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.
NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18, 2016 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com
NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com
NASA STENNIS SPACE CENTER, MISS – NASA engineers successfully carried out a key developmental test firing of an RS-25 rocket engine along with its modernized ‘brain’ controller at the Stennis Space Center on Thursday, Aug. 18, as part of the ongoing huge development effort coordinating the agency’s SLS Mars mega rocket slated for its maiden blastoff by late 2018.
“Today’s test was very successful,” Steve Wofford, manager of the SLS Liquid Engines Office at NASA’s Marshall Space Flight Center in Huntsville, Alabama, told Universe Today in an exclusive interview at the conclusion of the exciting RS-25 engine test gushing a huge miles long plume of steam at NASA Stennis on Aug. 18 under sweltering Gulf Coast heat.
“It was absolutely great!”
Thursday’s full thrust RS-25 engine hot fire test, using engine No. 0528, ran for its planned full duration of 7.5 minutes and met a host of critical test objectives required to confirm and scope out the capabilities and operating margins of the upgraded engines ,which are recycled from the shuttle era.
“We ran a full program duration of 420 seconds . And we had no failure identifications pop up.”
“It looks like we achieved all of our data objectives,” Wofford elaborated to Universe Today, after we witnessed the test from a viewing area just a few hundred meters away, with our ears protected by ear plugs.
A cluster of four RS-25 engines will power the Space Launch System (SLS) at the base of the first stage, also known as the core stage.
Huge plume of steam gushes as NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss., in this panoramic view. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com
SLS is the most powerful booster the world has even seen and one day soon will propel NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!
NASA’s goal is to send humans to Mars by the 2030s with SLS and Orion.
Ignition of the RS-25 engine creates a huge plume of steam gushing out the test stand during successful hot fire development test on Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss., in this panoramic view. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com
The primary goal of the development tests is to validate the capabilities of a new controller – or, “brain” – for the engine and to verify the different operating conditions needed for the SLS vehicle.
The test was part of a long continuing and new series aimed at certifying the engines for flight.
“We continue this test series in the fall. Which is a continuing part of our certification series to fly these engines on NASA’s SLS vehicle,” Wofford told me.
What was the primary objective of today’s test?
“Today’s test was mostly about wringing out the new control system. We have a new engine controller on this engine. And we have to certify that new controller for flight.”
“So to certify it we run it through its paces in ground tests. And we put it through a more stringent set of test conditions than it will ever see in flight.”
“The objectives we tested today required 420 seconds of testing to complete.”
Watch this NASA video of the full test:
Video Caption: RS-25 Rocket Engine Test Firing on 18 Aug. 2016: The 7.5-minute test conducted at NASA’s Stennis Space Center is part of a series of tests designed to put the upgraded former space shuttle engines through the rigorous temperature and pressure conditions they will experience during a launch of NASA’s Space Launch System mega rocket. Credit: NASA
What are the additional objectives from today’s test?
“Well you can’t do all of your objectives in one test. So the certification series are all about technical objectives and total accumulated time. So one thing we did was we accumulated time toward the time we need to certify this control system for the SLS engine,” Wofford explained.
“The other thing we did was you pick some technical objectives you want to put the controller through its paces for. And again you can’t do all of those in one test. So you spread them over a series. And we did some of those on this test.”
Aerojet Rocketdyne is the prime contractor for the RS-25 engine work and originally built them during the shuttle era.
The remaining cache of 16 heritage RS-25 engines are being recycled from their previous use as reusable space shuttle main engines (SSMEs). They are now being refurbished, upgraded and tested by NASA and Aerojet Rocketdyne to power the core stage of the Space Launch System rocket now under full development.
During launch they will fire at 109 percent thrust level for some eight and a half minutes while generating a combined two million pounds of thrust.
The SLS core stage is augmented with a pair of five segment solid rocket boosters (SRBs) generating about 3.3 million pounds of thrust each. NASA and Orbital just completed the QM-2 SRB qualification test on June 28.
Each of the RS-25’s engines generates some 500,000 pounds of thrust. They are fueled by cryogenic liquid hydrogen (LH2) and liquid oxygen (LOX).
The first liquid hydrogen (LH2) qualification fuel tank for the core stage was just welded together at NASA’s Michoud Assembly Facility in New Orleans – as I witnessed exclusively and reported here.
The first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The RS-25 engines measure 14 feet tall and 8 feet in diameter.
For SLS they will be operating at 109% of power – a higher power level compared to a routine usage of 104.5% during the shuttle era.
They have to withstand and survive temperature extremes ranging from -423 degrees F to more than 6000 degrees F.
Why was about five seconds of Thursday’s test run at the 111% power level? Will that continue in future tests?
“We did that because we plan to fly this engine on SLS at 109% of power level. So it’s to demonstrate the feasibility of doing that. On shuttle we were certified to fly these engines at 109%,” Wofford confirmed to Universe Today.
“So to demonstrate the feasibility of doing 109% power level on SLS we ‘overtest’ . So we ran [today’s test] at 2 % above where we are going to fly in flight.”
“We will do more in the future.”
The fully assembled core stage intergrated with all 4 RS-25 flight engines will be tested at the B-2 test stand in Stennis during the first quarter of 2018 – some 6 months or more before the launch in late 2018.
How many more engines tests will be conducted prior to the core stage test?
“After today we will run 7 more tests before the core stage test and the first flight.”
“I’m thrilled. I’ve see a lot of these and it never gets old!” Wofford gushed.
The hardware for SLS and Orion is really coming together now and its becoming more and more real every day.
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
These are exciting times for NASA’s human deep space exploration strategy.
The maiden test flight of the SLS/Orion is targeted for no later than November 2018 and will be configured in its initial 70-metric-ton (77-ton) Block 1 configuration with a liftoff thrust of 8.4 million pounds – more powerful than NASA’s Saturn V moon landing rocket.
Although the SLS-1 flight in 2018 will be uncrewed, NASA plans to launch astronauts on the SLS-2/EM-2 mission slated for the 2021 to 2023 timeframe.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Steve Wofford, manager of the SLS Liquid Engines Office at NASA’s Marshall Space Flight Center in Huntsville, Alabama, interviewed by Ken Kremer, Universe Today about the RS-25 hot fire engine test on Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power NASA’s Space Launch System (SLS) rocket. Credit: Ken Kremer/kenkremer.com
A crane lifts the Crew Access Arm and White Room for Boeing's CST-100 Starliner spacecraft for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com
A crane lifts the Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com
CAPE CANAVERAL AIR FORCE STATION, FL — A new ‘Stairway to Heaven’ which American astronauts will soon stride along as “the last place on Earth” departure point aboard our next generation of human spaceships, was at long last hoisted into place at the ULA Atlas rocket launch pad on Florida’s Space Coast on Monday Aug 15, at an “awesome” media event witnessed by space journalists including Universe Today.
“This is awesome,” Chris Ferguson, a former shuttle commander who is now Boeing’s deputy program manager for the company’s Commercial Crew Program told Universe Today in an exclusive interview at the launch pad – after workers finished installing the spanking new Crew Access Arm walkway for astronauts leading to the hatch of Boeing’s Starliner ‘Space Taxi.’
Starliner will ferry crews to and from the International Space Station (ISS) as soon as 2018.
“It’s great to see the arm up there,” Ferguson elaborated to Universe Today. “I know it’s probably a small part of the overall access tower. But it’s the most significant part!”
“We used to joke about the 195 foot level on the shuttle pad as being ‘the last place on Earth.”
“This will now be the new ‘last place on Earth’! So we are pretty charged up about it!” Ferguson gushed.
Up close view of Boeing Starliner Crew Access Arm and White Room craned into place at Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016. Credit: Dawn Leek Taylor
Under hot sunny skies portending the upcoming restoration of America’s ability to once again launch American astronauts from American soil when American rockets ignite, the newly constructed 50-foot-long, 90,000-pound ‘Crew Access Arm and White Room’ was lifted and mated to the newly built ‘Crew Access Tower’ at Space Launch Complex-41 (SLC-41) on Monday morning, Aug. 15.
“We talked about how the skyline is changing here and this is one of the more visible changes.”
The Boeing CST-100 Starliner crew capsule stacked atop the venerable United Launch Alliance (ULA) Atlas V rocket at pad 41 on Cape Canaveral Air Force Station in Florida will launch crews to the massive orbiting science outpost continuously soaring some 250 miles (400 km) above Earth.
Space workers, enthusiasts and dreamers alike have been waiting years for this momentous day to happen. And I was thrilled to observe all the action firsthand along with the people who made it happen from NASA, United Launch Alliance, Boeing, the contractors – as well as to experience it with my space media colleagues.
“All the elements that we talked about the last few years are now reality,” Ferguson told me.
The Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft approaches the notch for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 at level 13 on Aug. 15, 2016, as workers observe from upper tower level. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com
Attaching the access arm is vital and visual proof that at long last America means business and that a renaissance in human spaceflight will commence in some 18 months or less when commercially built American crew capsules from Boeing and SpaceX take flight to the heavens above – and a new space era of regular, robust and lower cost space flights begins.
It took about an hour for workers to delicately hoist the gleaming grey steel and aluminum white ‘Stairway to Heaven’ by crane into place at the top of the tower – at one of the busiest launch pads in the world!
It’s about 130 feet above the pad surface since it’s located at the 13th level of the tower.
The install work began at about 7:30 a.m. EDT as we watched a work crew lower a giant grappling hook and attach cables. Then they carefully raised the arm off the launch pad surface by crane. The arm had been trucked to the launch pad on Aug. 11.
The tower itself is comprised of segmented tiers that were built in segments just south of the pad. They were stacked on the pad over the past few months – in between launches. Altogether they form a nearly 200-foot-tall steel structure.
Another crew stationed in the tower about 160 feet above ground waited as the arm was delicately craned into the designated notch. The workers then spent several more hours methodically bolting and welding the arm to the tower to finish the assembly process.
Indeed Monday’s installation of the Crew Access Arm and White Room at pad 41 basically completes the construction of the first new Crew Access Tower at Cape Canaveral Air Force Station since the Apollo moon landing era of the 1960s.
“It is the first new crew access structure at the Florida spaceport since the space shuttle’s Fixed Service Structures were put in place before Columbia’s first flight in 1981,” say NASA officials.
Overall the steel frame of the massive tower weighs over a million pounds. For perspective, destination ISS now weighs in at about a million pounds in low Earth orbit.
Construction of the tower began about 18 months ago.
“You think about when we started building this 18 months ago and now it’s one of the most visible changes to the Cape’s horizon since the 1960s,” said Ferguson at Monday’s momentous media event. “It’s a fantastic day.”
The White Room is an enclosed area at the end of the Crew Access Arm. It big enough for astronauts to make final adjustments to their suits and is spacious enough for technicians to assist the astronauts climbing aboard the spacecraft and get tucked into their seats in the final hours before liftoff.
“You have to stop and celebrate these moments in the craziness of all the things we do,” said Kathy Lueders, manager of NASA’s Commercial Crew Program, at the event. “It’s going to be so cool when our astronauts are walking out across this access arm to get on the spacecraft and go to the space station.”
The Crew Access Arm was built by Saur at NASA’s nearby off site facility at Oak Hill.
And when Starliner takes flight it will hearken back to the dawn of the Space Age.
“John Glenn was the first to fly on an Atlas, now our next leap into the future will be to have astronauts launch from here on Atlas V,” said Barb Egan, program manager for Commercial Crew for ULA.
Boeing is manufacturing Starliner in what is officially known as Boeing’s Commercial Crew and Cargo Processing Facility (C3PF) at the Kennedy Space Center in Florida under contract with NASA’s Commercial Crew Program (CCP).
Hull of the Boeing CST-100 Starliner Structural Test Article (STA)- the first Starliner to be built in the company’s modernized Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
The Boeing CST 100 Starliner is one of two private astronaut capsules – along with the SpaceX Crew Dragon – being developed under a CCP commercial partnership contract with NASA to end our sole reliance on Russia for crew launches back and forth to the International Space Station (ISS).
The goal of NASA’s Commercial Crew Program since its inception in 2010 is to restore America’s capability to launch American astronauts on American rockets from American soil to the ISS, as soon as possible.
Furthermore when the Boeing Starliner and SpaceX Crew Dragon become operational the permanent resident ISS crew will grow to 7 – enabling a doubling of science output aboard the science laboratory.
This significant growth in research capabilities will invaluably assist NASA in testing technologies and human endurance in its agency wide goal of sending humans on a ‘Journey to Mars’ by the 2030s with the mammoth Space Launch System (SLS) rocket and Orion deep space capsule concurrently under full scale development by the agency.
The next key SLS milestone is a trest firing of the RS-25 main engines at NASA Stennis this Thursday, Aug. 18 – watch for my onsite reports!
Boeing was awarded a $4.2 Billion contract in September 2014 by NASA Administrator Charles Bolden to complete development and manufacture of the CST-100 Starliner space taxi under the agency’s Commercial Crew Transportation Capability (CCtCap) program and NASA’s Launch America initiative.
Since the retirement of NASA’s space shuttle program in 2011, the US was been 100% dependent on the Russian Soyuz capsule for astronauts rides to the ISS at a cost exceeding $70 million per seat.
When will Ferguson actually set foot inside the walkway?
“I am hoping to get up there and walk through there in a couple of weeks or so when it’s all strapped in and done. I want to see how they are doing and walk around.”
How does the White Room fit around Starliner and keep it climate controlled?
“The end of the white room has a part that slides up and down and moves over and slides on top of the spacecraft when it’s in place.”
“There is an inflatable seal that forms the final seal to the spacecraft so that you have all the appropriate humidity control and the purge without the Florida atmosphere inside the crew module,” Ferguson replied.
Up close, mid-air view of Crew Access Arm and front of White Room during installation. The White Room will fit snugly against Boeing’s CST-100 Starliner spacecraft with inflatable seal to maintain climate control and clean conditions as astronauts board capsule atop Atlas rocket hours before launch on United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com
Boeing and NASA are targeting Feb. 2018 for launch of the first crewed orbital test flight on the Atlas V rocket. The Atlas will be augmented with two solid rocket motors on the first stage and a dual engine Centaur upper stage.
How confident is Ferguson about meeting the 2018 launch target?
“The first crew flight is scheduled for February 2018. I am confident.” Ferguson responded.
“And we have a lot of qualification to get through between now and then. But barring any large unforeseen issues we can make it.”
The Crew Access Tower after installation of the Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft on Aug. 15, 2016 at Space Launch Complex 41 on Cape Canaveral Air Force Station, Fl. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.
As the Boeing Starliner Crew Access Arm and White Room are bolted into place behind us at Space Launch Complex 41, Chris Ferguson, former shuttle commander and current Boeing deputy program manager for Commercial Crew, and Ken Kremer of Universe Today discuss the future of human spaceflight on Aug. 15, 2016 at Cape Canaveral Air Force Station. Credit: Jeff Seibert
Hull of the Boeing CST-100 Starliner Structural Test Article (STA)- the first Starliner to be built in the company’s modernized Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Hull of the Boeing CST-100 Starliner Structural Test Article (STA)- the first Starliner to be built in the company’s modernized Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
KENNEDY SPACE CENTER, FL – The next generation of America’s human spaceships is rapidly taking shape and “making fantastic progress” at the Kennedy Space Center as Boeing and NASA showcased the start of assembly of the first flightworthy version of the aerospace giants Starliner crew taxi vehicle to the media last week. Starliner will ferry NASA astronauts to and from the International Space Station (ISS) by early 2018.
“We are making fantastic progress across the board,” John Mulholland, vice president and program manager of Boeing Commercial Programs, told Universe Today at the July 26 media event in Boeing’s new Starliner factory.
“It so nice to move from design to firm configuration, which was an incredibly important milestone, to now moving into the integrated qual phase of the campaign.”
Boeing is swiftly making tangible progress towards once again flying Americans astronauts to space from American soil as was quite visibly demonstrated when the firm showed off their spanking new Starliner ‘clean-floor factory’ to the media last week, including Universe Today – and it’s already humming with activity by simultaneously building two full scale Starliner crew vehicles.
“We are on track to support launch by the end of 2017 [of the uncrewed orbital test flight],” Mulholland told me.
“The Structural Test Article (STA) crew module is almost ready to be delivered to the test site in California. The service module is already delivered at the test site. So we are ready to move into the qualification campaign.”
“We are also in the middle of component qualification and qualifying more than one component every week as we really progress into assembly, integration and test of flight design spacecrafts.”
Starliner is being manufactured in what is officially known as Boeing’s Commercial Crew and Cargo Processing Facility (C3PF) at the Kennedy Space Center in Florida under contract with NASA’s Commercial Crew Program (CCP).
And the Boeing CST-100 Starliner assembly line aiming to send our astronauts to low Earth orbit and the space station is now operating full speed ahead at KSC.
Formerly known as Orbiter Processing Facility-3, or OPF-3, the facility was previously used as a servicing hanger to prepare NASA’s space shuttle orbiters for flight.
NASA, industry and news media representatives visit the modernized high bay in Boeing’s Commercial Crew and Cargo Processing Facility at NASA’s Kennedy Space Center in Florida. Credits: NASA/Kim Shiflett
The facility has now been completely renovated and refurbished by removing about 11,000 tons of massive steel work platforms that once enshrouded the space shuttle orbiters for servicing and refurbishment for flight – and been transformed into Boeings gleaming white C3PF Starliner manufacturing facility.
Components for the first Starliner that will actually fly in space – known as Spacecraft 1 – began arriving recently at the C3PF. These include the upper and lower domes, as well as the docking hatch for the spacecrafts pressure vessel.
“You can see the beginning of Spacecraft 1. To build it all of the major structural elements are here,” Mulholland explained.
“The lower dome will be populated and get to first power on early next year. We are really looking forward to that. Then we will mate that to the upper dome and start in on the ground qualification on Spacecraft 1.”
Altogether Boeing is fabricating three Starliner flight spacecraft.
“We will start building Spacecraft 2 in the Fall of this year. And then we will start Spacecraft 3 early next year.”
“So we will have three Starliner spacecraft flight crew module builds as we move into the flight campaign.”
The honeycombed upper dome of a Boeing Starliner spacecraft on a work stand inside the company’s Commercial Crew and Cargo Processing Facility at NASA’s Kennedy Space Center in Florida. The upper dome is part of Spacecraft 1 , the first flightworthy Starliner being developed in partnership with NASA’s Commercial Crew Program. Credit: Ken Kremer/kenkremer.com
Technicians are outfitting these individual components of the pressure vessel with wiring and lines, avionics and other systems, before they are bolted together.
Spacecraft 1 is actually the second Starliner being manufactured at the Kennedy Space Center.
The first full scale Starliner vehicle to be built is known as the Structural Test Article (STA) and is nearing completion.
The lower dome of the Boeing Starliner Spacecraft 1 assembly being outfitted with flight systems like wiring, lines, avionics in the firm’s Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Notably Spacecraft 1 will be the first Starliner to fly in the company’s pad abort test.
“Spacecraft 1 will go into the ground campaign and then the pad abort,” Mulholland stated.
“The test is designed to prove the launch abort system planned for the spacecraft will be able to lift astronauts away from danger in the event of an emergency during launch operations,” says NASA.
The Pad Abort test is currently slated for October 2017 in New Mexico. Boeing will fly an uncrewed orbital flight test in December 2017 and a crewed orbital flight test in February 2018.
“Spacecraft 3 will be the first to fly in orbit on the uncrewed flight test by the end of 2017,” Mulholland confirmed.
‘Spacecraft 2 will go through a several month long thermal vac testing and EMI and EMC in California in the middle of next year and then go into the crewed flight test [in 2018].”
The rather distinctive, olive colored aluminum domes are manufactured using a weldless spin forming process by Spincraft, based in North Billerica, Massachusetts.
They take on their honeycombed look after being machined for the purposes of reducing weight and increasing strength to handle the extreme stresses of spaceflight. The lower dome is machined by Janicki Industries in Layton, Utah, and the upper dome is machined by Major Tool & Machine in Indianapolis.
Overhead view of the docking hatch for the Boeing Starliner Spacecraft 1 assembly which technicians will soon join to the upper dome in the firm’s Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Engineers bolted together the upper and lower domes of Boeings maiden Starliner crew module in early May to form the complete hull of the pressure vessel for the Structural Test Article (STA).
Altogether they are held together by 216 bolts. They have to line up perfectly. And the seals are checked to make sure there are no leaks, which could be deadly in space.
Boeing expects to finish fabricating the STA by August.
The completed Starliner STA will then be transported to Boeing’s facility in Huntington Beach, California for a period of critical stress testing that verifies the capabilities and worthiness of the spacecraft.
“Boeing’s testing facility in Huntington Beach, California has all the facilities to do the structural testing and apply loads. They are set up to test spacecraft,” said Danom Buck, manager of Boeing’s Manufacturing and Engineering team at KSC, during an interview in the C3PF.
“At Huntington Beach we will test for all of the load cases that the vehicle will fly in and land in – so all of the worst stressing cases.”
“So we have predicted loads and will compare that to what we actually see in testing and see whether that matches what we predicted.”
Boeing has also vastly updated the mockup Starliner to reflect the latest spacecraft advances and assist in manufacturing the three planned flight units.
Bastian Technologies built many of the components for the mockup and signed as new 18-month new Mentor-Protégé Program agreement with Boeing and NASA at the media event.
The mock up “is used as a hands-on way to test the design, accessibility and human factors during the early design and development phase of the program. The mock-up is currently being used for rapid fire engineering verification activities, ergonomic evaluations [including the seats and display panels], and crew ingress and egress training,” says NASA.
Looking inside the newly upgraded Starliner mockup with display panel, astronauts seats, gear and hatch at top that will dock to the new International Docking Adapter (IDA) on the ISS. Credit: Ken Kremer/kenkremer.com
The Boeing CST 100 Starliner is one of two private astronaut capsules – along with the SpaceX Crew Dragon – being developed under a commercial partnership contract with NASA to end our sole reliance on Russia for crew launches back and forth to the International Space Station (ISS).
The goal of NASA’s Commercial Crew Program (CCP) is to restore America’s capability to launch American astronauts on American rockets from American soil to the ISS, as soon as possible.
Boeing was awarded a $4.2 Billion contract in September 2014 by NASA Administrator Charles Bolden to complete development and manufacture of the CST-100 Starliner space taxi under the agency’s Commercial Crew Transportation Capability (CCtCap) program and NASA’s Launch America initiative.
Since the retirement of NASA’s space shuttle program in 2011, the US was been 100% dependent on the Russian Soyuz capsule for astronauts rides to the ISS at a cost exceeding $70 million per seat.
Starliners will launch to space atop the United Launch Alliance (ULA) Atlas V rocket from pad 41 on Cape Canaveral Air Force Station in Florida.
The Boeing Starliner will launch on a United Launch Alliance (ULA) Atlas V rocket similar to the one carrying the NROL-61 surveillance satellite for the National Reconnaissance Office (NRO) from Space Launch Complex-41 on July 28, 2016 at 8:37 a.m. EDT from Cape Canaveral Air Force Station, FL. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.
Ken Kremer Boeing ‘Starliner’ commercial crew space taxi manufacturing facility at the Kennedy Space Center. Exterior view depicts mural for the Boeing Company’s recently named CST-100 ‘Starliner’ commercial crew transportation spacecraft on the company’s Commercial Crew and Cargo Processing Facility (C3PF) at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer /kenkremer.com
John Mulholland, vice president and program manager of Boeing Commercial Programs, and Ken Kremer, Universe Today, discuss status and assembly of 1st flightworthy Boeing Starliner by the new Starliner mockup in the Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Starliner will transport US astronauts to the ISS by 2018. Credit: Julian Leek
Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016 during exclusive facility visit by Universe Today. The new platforms are required to give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016 during exclusive facility visit by Universe Today. The new platforms give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
“We are in the full development stage right now and roughly 50% complete with the platforms on this job,” David Sumner, GSDO Deputy Sr. project manager for VAB development work at KSC, told Universe Today in an exclusive interview inside the VAB’s High Bay 3 on July 28, amidst workers actively turning NASA’s deep space dreams into full blown reality. See our exclusive up close photos herein – detailing the huge ongoing effort.
Upgrading and renovating the VAB is specifically the responsibility of NASA’s Ground Systems Development and Operations Program (GSDO) at Kennedy.
Inside VAB High Bay 3 – where previous generations of space workers proudly assembled NASA’s Saturn V Moon rocket and the Space Shuttle Orbiter launch stacks – today’s crews of workers were actively installing the newly manufactured work platforms needed to process and build the agency’s Space Launch System (SLS) rocket that will soon propel our astronauts back to exciting deep space destinations.
“We are very excited. We are at the beginning of a new program!” Sumner told me. “We have the infrastructure and are getting into operations soon.”
A heavy-lift crane lifts the first half of the F-level work platforms, F south, for NASA’s Space Launch System rocket, into position for installation July 15, in High Bay 3 of the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. Photo credit: NASA/Bill White
It’s certainly an exciting time as NASA pushes forward on all fronts in a coordinated nationwide effort to get the SLS rocket with the Orion EM-1 crew vehicle bolted on top ready and rolled out to Kennedy’s pad 39B for their planned maiden integrated blastoff by Fall 2018.
SLS and Orion are at the heart of NASA’s agency wide strategy to send astronauts on a ‘Journey to Mars’ by the 2030s.
SLS is the most powerful booster the world has even seen and is designed to boost NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!
I walked into High Bay 3, scanned all around and up to the ceiling some 525 feet away and was thrilled to see a bustling construction site – the future of human voyages in deep space unfolding before my eyes. As I looked up to see the newly installed work platforms, I was surrounded by the constant hum of plenty of hammering, cutting, welding, hoisting, fastening, banging and clanging and workers moving equipment and gear around.
Welding work in progress by workers in the VAB transfer aisle for installation of huge work platforms inside High Bay 3 at KSC on July 28, 2016. Credit: Julian Leek
Altogether a total of 10 levels of work platform levels will be installed in High Bay 3 – labeled K to A, from bottom to top. Each level consists of two platform halves, denoted as the North and South side platforms.
Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016. Heavy duty cranes are used to install the new platforms which will enable access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian Leek
What’s the status today?
“We are looking up at 5 of 10 platform levels with 10 of 20 platform halves installed here. A total of ten levels are being installed,” Sumner explained.
“We are installing them from the bottom up. The bottom five levels are installed so far.”
“We are up to about the 190 foot level right now with Platform F installation. Then we are going up to about the 325 foot level with the 10th platform [Platform A].
“So there are 10 levels for EM-1.”
Up close view looking out to the edge of Platform F showing the outer mold line snaking around the SLS core stage and a solid rocket booster from the 190 foot level under construction inside the VAB High Bay 3 on July 28, 2016 at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
So much work was visible and actively in progress I definitely got the feeling from the ground up that NASA is now rapidly moving into the new post shuttle Era – dominated by the mammoth new SLS making its assembly debut inside these hallowed walls some 18 months or so from today.
“The work today is some outfitting on the platforms overhead here, as well as more work on the platform halves sitting in the transfer aisle and High Bay 4 to get them ready to lift and install into High Bay 3.”
“Overhead steel work is also ongoing here in High Bay 3 with additional steel work going vertical for reinforcement and mounting brackets for all the platforms going vertically.”
“So quite a few work locations are active with different crews and different groups.”
Two additional new platform halves are sitting in the VAB transfer aisle and are next in line for installation. With two more awaiting in VAB High Bay 4. Fabrication of additional platform halves is ongoing at KSC’s nearby Oak Hill facility.
“The rest are being fabricated in our Oak Hill facility. So we have almost everything on site so far.”
Two halves of Platform D sit in the VAB transfer aisle on July 28, 2016 awaiting installation into High Bay 3. The new platforms give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Hensel Phelps is the general contractor for the VAB transformation. Subcontractors include S&R, Steel LLC, Sauer Inc., Jacobs and Beyel Bros Crane and Rigging.
The work platforms enable access to the SLS rocket at different levels up and down the over 300 foot tall rocket topped by the Orion crew capsule. They will fit around the outer mold line of SLS – including the twin solid rocket boosters, the core stage, and upper stage – and Orion.
The SLS core stage is being manufactured at NASA’s Michoud Assembly Facility in New Orleans, where I recently inspected the first completed liquid hydrogen tank test article – as reported here. Orion EM-1 is being manufactured here at Kennedy – as I reported here.
The first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The platforms will provide access for workers to assemble, process and test all the SLS and Orion components before rolling out to Launch Complex 39B atop the 380 foot tall Mobile Launcher – which is also undergoing a concurrent major renovation and overhaul.
As of today, five of the ten levels of platforms are in place.
Each of the giant platforms made of steel measures about 38 feet long and close to 62 feet wide. They weigh between 300,000 and 325,000 pounds.
The most recently installed F North and South platforms were put in place on the north and south walls of the high bay on July 15 and 19, respectively.
Here’s the view looking out to Platform F:
View looking out to both halves of Platform F and down to Platform G showing the outer mold line snaking around the SLS core stage and a solid rocket booster from the 190 foot level under construction inside the VAB High Bay 3 on July 28, 2016 at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
How are the platforms installed ?
The platforms are carefully lifted into place by workers during a process that lasts about four hours.
“The 325 and 250 ton overhead facility cranes are used to [slowly] lift and move the platform halves back and forth between the VAB transfer aisle and High Bay 4 and into the SLS High Bay 3.”
Then they are attached to rail beams on the north and south walls of the high bay.
Construction workers from Beyel Bros Crane and Rigging also use a Grove 40 ton all terrain crane. It is also outfitted with man baskets to get to the places that cannot be reached by scaffolding in High Bay 3.
Installation of the remaining five levels of platforms should be completed by mid-2017.
“The job will be done by the middle of 2017. All the construction work will be done,” Sumner explained.
“Then we will get into our verification and validations with the Mobile Launcher (ML). Then the ML will roll in here around middle to late 2017 [for checkouts and testing] and then roll out to the pad [for more testing]. After that it will roll back in here. Then we will be ready to stack the SLS starting after that!”
Looking up from beneath the enlarged exhaust hole of the Mobile Launcher to the 380 foot-tall tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft during Exploration Mission-1 at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
The platforms will be tested beginning later this year, starting with the lowest platforms at the K-level, and working all the way up to the top, the A-level.
The platforms are attached to a system of rail beams that “provide structural support and contain the drive mechanisms to retract and extend the platforms,” according to a NASA fact sheet.
“Each platform will reside on four Hillman roller systems on each side – much like a kitchen drawer slides in and out. A mechanical articulated tray also moves in and out with each platform.”
The F-level platforms are located about 192 feet above the VAB floor.
“They will provide access to the SLS core stage (CS) intertank for umbilical mate operations. The “F-1” multi-level ground support equipment access platform will be used to access the booster forward assemblies and the CS to booster forward attach points. The upper level of F-1 will be used to remove the lifting sling used to support forward assembly mate for booster stacking operations.”
“Using the five platforms that are now installed, workers will have access to all of the Space Launch System rocket’s booster field joints and forward skirts, the core stage intertank umbilical and interface plates,” says Mike Bolger, GSDO program manager at Kennedy.
Looking 190 feet down from Platform F to the VAB floor along all five newly installed access platforms in High Bay 3. Construction worker on Platform G below is working near the outer mold line for the SLS rocket that will fill this space by early 2018 at KSC in Florida. Credit: Ken Kremer/kenkremer.com
‘NASA is transforming KSC into a launch complex for the 21st Century,’ as KSC Center Director and former shuttle commander Bob Cabana often explains.
So it was out with the old and in with the new to carry out that daunting task.
“We took the old shuttle platforms out, went down to the [building] structure over the past few years and are now putting up the new SLS platforms,” Sumner elaborated.
“All the demolition work was done a few years ago. So we are in the full development stage right now and roughly 50% complete with the platforms on this job.”
And after NASA launches EM-1, significantly more VAB work lies ahead to prepare for the first manned Orion launch on the EM-2 mission set for as soon as 2021 – because it will feature an upgraded and taller version of the SLS rocket – including a new upper stage.
“For EM-2, the plan right now is we will add two more levels and relocate three more. So we will do some adjustments and new installations in the upper levels for EM-2.”
“It’s been an honor to be here and work here in the VAB every day – and prepare for the next 50 years of its life.”
“We are at the beginning of a new program. We have the infrastructure and are getting into operations soon,” Sumner said. “We have hopefully got a long way to go on the future of space exploration, with many decades of exploration ahead.”
“We are on a ‘Journey to Mars’ and elsewhere. So this is the beginning of all that. It’s very exciting!”
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Looking down from newly installed VAB High Bay 3 Platform F to Platform G on July 28, 2016. New platforms enable access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian LeekTwo halves of Platform D sit in the VAB transfer aisle on July 28, 2016 awaiting installation into High Bay 3. The new platforms give technicians access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian LeekLooking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016 during exclusive facility visit by Universe Today. The new platforms are required to give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.comUS Flag hangs proudly inside the VAB – America’s Premier Spaceport to Deep Space. Credit: Lane Hermann View of the VAB and Mobile Launcher from the KSC Launch Complex 39 Press Site. NASA is upgrading the VAB with new platforms to assemble and launch NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com Floor level view of the Mobile Launcher and enlarged exhaust hole with 380 foot-tall launch tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft for launches from Space Launch Complex 39B the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
The first liquid hydrogen tank, also called the qualification test article, for NASA's new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
MICHOUD ASSEMBLY FACILITY, NEW ORLEANS, LA – NASA has just finished welding together the very first fuel tank for America’s humongous Space Launch System (SLS) deep space rocket currently under development – and Universe Today had an exclusive up close look at the liquid hydrogen (LH2) test tank shortly after its birth as well as the first flight tank, during a tour of NASA’s New Orleans rocket manufacturing facility on Friday, July 22, shortly after completion of the milestone assembly operation.
“We have just finished welding the first liquid hydrogen qualification tank article …. and are in the middle of production welding of the first liquid hydrogen flight hardware tank [for SLS-1] in the big Vertical Assembly Center welder!” explained Patrick Whipps, NASA SLS Stages Element Manager, in an exclusive hardware tour and interview with Universe Today on July 22, 2016 at NASA’s Michoud Assembly Facility (MAF) in New Orleans.
“We are literally putting the SLS rocket hardware together here at last. All five elements to put the SLS stages together [at Michoud].”
This first fully welded SLS liquid hydrogen tank is known as a ‘qualification test article’ and it was assembled using basically the same components and processing procedures as an actual flight tank, says Whipps.
“We just completed the liquid hydrogen qualification tank article and lifted it out of the welding machine and put it into some cradles. We will put it into a newly designed straddle carrier article next week to transport it around safely and reliably for further work.”
And welding of the liquid hydrogen flight tank is moving along well.
“We will be complete with all SLS core stage flight tank welding in the VAC by the end of September,” added Jackie Nesselroad, SLS Boeing manager at Michoud. “It’s coming up very quickly!”
“The welding of the forward dome to barrel 1 on the liquid hydrogen flight tank is complete. And we are doing phased array ultrasonic testing right now!”
SLS is the most powerful booster the world has even seen and one day soon will propel NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!
The LH2 ‘qualification test article’ was welded together using the world’s largest welder – known as the Vertical Assembly Center, or VAC, at Michoud.
And it’s a giant! – measuring approximately 130-feet in length and 27.6 feet (8.4 m) in diameter.
See my exclusive up close photos herein documenting the newly completed tank as the first media to visit the first SLS tank. I saw the big tank shortly after it was carefully lifted out of the welder and placed horizontally on a storage cradle on Michoud’s factory floor.
The newly assembled first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
Finishing its assembly after years of meticulous planning and hard work paves the path to enabling the maiden test launch of the SLS heavy lifter in the fall of 2018 from the Kennedy Space Center (KSC) in Florida.
The qual test article is the immediate precursor to the actual first LH2 flight tank now being welded.
“We will finish welding the liquid hydrogen and liquid oxygen flight tanks by September,” Whipps told Universe Today.
Up close view of the dome of the newly assembled first ever liquid hydrogen test tank for NASA’s new Space Launch System (SLS) heavy lift rocket on July 22, 2016 after it was welded together at NASA’s Michoud Assembly Facility in New Orleans. Sensors will be attached to both ends for upcoming structural loads and proof testing. Credit: Ken Kremer/kenkremer.com
Technicians assembled the LH2 tank by feeding the individual metallic components into NASA’s gigantic “Welding Wonder” machine – as its affectionately known – at Michoud, thus creating a rigid 13 story tall structure.
The welding work was just completed this past week on the massive silver colored structure. It was removed from the VAC welder and placed horizontally on a cradle.
I watched along as the team was also already hard at work fabricating SLS’s first liquid hydrogen flight article tank in the VAC, right beside the qualification tank resting on the floor.
Welding of the other big fuel tank, the liquid oxygen (LOX) qualification and flight article tanks will follow quickly inside the impressive ‘Welding Wonder’ machine, Nesselroad explained.
The LH2 and LOX tanks sit on top of one another inside the SLS outer skin.
The SLS core stage – or first stage – is mostly comprised of the liquid hydrogen and liquid oxygen cryogenic fuel storage tanks which store the rocket propellants at super chilled temperatures. Boeing is the prime contractor for the SLS core stage.
To prove that the new welding machines would work as designed, NASA opted “for a 3 stage assembly philosophy,” Whipps explained.
Engineers first “welded confidence articles for each of the tank sections” to prove out the welding techniques “and establish a learning curve for the team and test out the software and new weld tools. We learned a lot from the weld confidence articles!”
“On the heels of that followed the qualification weld articles” for tank loads testing.
“The qualification articles are as ‘flight-like’ as we can get them! With the expectation that there are still some tweaks coming.”
“And finally that leads into our flight hardware production welding and manufacturing the actual flight unit tanks for launches.”
“All the confidence articles and the LH2 qualification article are complete!”
What’s the next step for the LH2 tank?
The test article tank will be outfitted with special sensors and simulators attached to each end to record reams of important engineering data, thereby extending it to about 185 feet in length.
Thereafter it will loaded onto the Pegasus barge and shipped to NASA’s Marshall Space Flight Center in Huntsville, Alabama, for structural loads testing on one of two new test stands currently under construction for the tanks. The tests are done to prove that the tanks can withstand the extreme stresses of spaceflight and safely carry our astronauts to space.
“We are manufacturing the simulators for each of the SLS elements now for destructive tests – for shipment to Marshall. It will test all the stress modes, and finally to failure to see the process margins.”
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
The SLS core stage builds on heritage from NASA’s Space Shuttle Program and is based on the shuttle’s External Tank (ET). All 135 ET flight units were built at Michoud during the thirty year long shuttle program by Lockheed Martin.
“We saved billions of dollars and years of development effort vs. starting from a clean sheet of paper design, by taking aspects of the shuttle … and created an External Tank type generic structure – with the forward avionics on top and the complex engine section with 4 engines (vs. 3 for shuttle) on the bottom,” Whipps elaborated.
“This is truly an engineering marvel like the External Tank was – with its strength that it had and carrying the weight that it did. If you made our ET the equivalent of a Coke can, our thickness was about 1/5 of a coke can.”
“It’s a tremendous engineering job. But the ullage pressures in the LOX and LH2 tanks are significantly more and the systems running down the side of the SLS tank are much more sophisticated. Its all significantly more complex with the feed lines than what we did for the ET. But we brought forward the aspects and designs that let us save time and money and we knew were effective and reliable.”
The Vertical Weld Center tool used to fabricate barrel segments for the SLS liquid hydrogen and oxygen core stage tanks via vertical friction stir welding operations at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The SLS core stage is comprised of five major structures: the forward skirt, the liquid oxygen tank (LOX), the intertank, the liquid hydrogen tank (LH2) and the engine section.
The LH2 and LOX tanks feed the cryogenic propellants into the first stage engine propulsion section which is powered by a quartet of RS-25 engines – modified space shuttle main engines (SSMEs) – and a pair of enhanced five segment solid rocket boosters (SRBs) also derived from the shuttles four segment boosters.
The tanks are assembled by joining previously manufactured dome, ring and barrel components together in the Vertical Assembly Center by a process known as friction stir welding. The rings connect and provide stiffness between the domes and barrels.
The LH2 tank is the largest major part of the SLS core stage. It holds 537,000 gallons of super chilled liquid hydrogen. It is comprised of 5 barrels, 2 domes, and 2 rings.
The LOX tank holds 196,000 pounds of liquid oxygen. It is assembled from 2 barrels, 2 domes, and 2 rings and measures over 50 feet long.
The material of construction of the tanks has changed compared to the ET.
“The tanks are constructed of a material called the Aluminum 2219 alloy,” said Whipps. “It’s a ubiquosly used aerospace alloy with some copper but no lithium, unlike the shuttle superlightweight ET tanks that used Aluminum 2195. The 2219 has been a success story for the welding. This alloy is heavier but does not affect our payload potential.”
“The intertanks are the only non welded structure. They are bolted together and we are manufacturing them also. It’s much heavier and thicker.”
Overall, the SLS core stage towers over 212 feet (64.6 meters) tall and sports a diameter of 27.6 feet (8.4 m).
NASA’s Vehicle Assembly Center is the world’s largest robotic weld tool. The domes and barrels are assembled from smaller panels and piece parts using other dedicated robotic welding machines at Michoud.
The total weight of the whole core stage empty is 188,000 pounds and 2.3 million pounds when fully loaded with propellant. The empty ET weighed some 55,000 pounds.
Considering that the entire Shuttle ET was 154-feet long, the 130-foot long LH2 tank alone isn’t much smaller and gives perspective on just how big it really is as the largest rocket fuel tank ever built.
“So far all the parts of the SLS rocket are coming along well.”
“The Michoud SLS workforce totals about 1000 to 1500 people between NASA and the contractors.”
Every fuel tank welded together from now on after this series of confidence and qualification LOX and LH2 tanks will be actual flight article tanks for SLS launches.
“There are no plans to weld another qualification tank after this,” Nesselroad confirmed to me.
What’s ahead for the SLS-2 core stage?
“We start building the second SLS flight tanks in October of this year – 2016!” Nesselroad stated.
The world’s largest welder was specifically designed to manufacture the core stage of the world’s most powerful rocket – NASA’s SLS.
The Vertical Assembly Center welder was officially opened for business at NASA’s Michoud Assembly Facility in New Orleans on Friday, Sept. 12, 2014.
NASA Administrator Charles Bolden was personally on hand for the ribbon-cutting ceremony at the base of the huge VAC welder.
The state-of-the-art welding giant stands 170 feet tall and 78 feet wide. It complements the world-class welding toolkit being used to assemble various pieces of the SLS core stage including the domes, rings and barrels that have been previously manufactured.
The Gore Weld Tool (foreground) and Circumferential Dome Weld Tool (background) used to fabricate dome segments for the SLS liquid hydrogen and oxygen core stage tanks via vertical friction stir welding operations at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The maiden test flight of the SLS/Orion is targeted for no later than November 2018 and will be configured in its initial 70-metric-ton (77-ton) Block 1 configuration with a liftoff thrust of 8.4 million pounds – more powerful than NASA’s Saturn V moon landing rocket.
Although the SLS-1 flight in 2018 will be uncrewed, NASA plans to launch astronauts on the SLS-2/EM-2 mission slated for the 2021 to 2023 timeframe.
The exact launch dates fully depend on the budget NASA receives from Congress and who is elected President in the November 2016 election – and whether they maintain or modify NASA’s objectives.
“If we can keep our focus and keep delivering, and deliver to the schedules, the budgets and the promise of what we’ve got, I think we’ve got a very capable vision that actually moves the nation very far forward in moving human presence into space,” said William Gerstenmaier, associate administrator for the Human Exploration and Operations Mission Directorate at NASA Headquarters in Washington, during the post QM-2 SRB test media briefing in Utah last month.
“This is a very capable system. It’s not built for just one or two flights. It is actually built for multiple decades of use that will enable us to eventually allow humans to go to Mars in the 2030s.”
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Learn more about SLS and Orion crew vehicle, SpaceX CRS-9 rocket launch, ISS, ULA Atlas and Delta rockets, Juno at Jupiter, Orbital ATK Antares & Cygnus, Boeing, Space Taxis, Mars rovers, NASA missions and more at Ken’s upcoming outreach events:
July 27-28: “ULA Atlas V NRO Spysat launch July 28, SpaceX launch to ISS on CRS-9, SLS, Orion, Juno at Jupiter, ULA Delta 4 Heavy NRO spy satellite, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings
Graphic shows all the dome, barrel, ring and engine components used to assemble the five major structures of the core stage of NASA’s Space Launch System (SLS) in Block 1 configuration. Credits: NASA/MSFCAt NASA’s Michoud Assembly Facility in New Orleans, Patrick Whipps/NASA SLS Stages Element Manager and Ken Kremer/Universe Today discuss details of SLS manufacture by the Circumferential Dome Weld Tool used to fabricate dome segments for the SLS liquid hydrogen and oxygen core stage tanks. Credit: Ken Kremer/kenkremer.comGraphic shows Block I configuration of NASA’s Space Launch System (SLS). Credits: NASA/MSFC
For decades, Canada has made significant contributions to the field of space exploration. These include the development of sophisticated robotics, optics, participation in important research, and sending astronauts into space as part of NASA missions. And who can forget Chris Hadfield, Mr. “Space Oddity” himself? In addition to being the first Canadian to command the ISS, he is also known worldwide as the man who made space exploration fun and accessible through social media.
And in recent statement, the Canadian Space Agency (CSA) has announced that it is looking for new recruits to become the next generation of Canadian astronauts. With two positions available, they are looking for applicants who embody the best qualities of astronauts, which includes a background in science and technology, exceptional physical fitness, and a desire to advance the cause of space exploration.
Over the course of the past few decades, the Canadian Space Agency has established a reputation for the development of space-related technologies. In 1962, Canada deployed the Alouette satellite, which made it the third nation – after the US and USSR – to design and build its own artificial Earth satellite. And in 1972, Canada became the first country to deploy a domestic communications satellite, known as Anik 1 A1.
The “Canadarm”, pictured here as part of Space Shuttle mission STS-2, it’s first deployment to space, in November of 1981. Credit: NASA
Perhaps the best-known example of Canada’s achievements comes in the field of robotics, and goes by the name of the Shuttle Remote Manipulator System (aka. “the Canadarm“). This robotic arm was introduced in 1981, and quickly became a regular feature within the Space Shuttle Program.
“Canadarm is the best-known example of the key role of Canada’s space exploration program,” said Maya Eyssen, a spokeperson for the CSA, via email. “Our robotic contribution to the shuttle program secured a mission spot for our nation’s first astronaut to fly to space –Marc Garneau. It also paved the way for Canada’s participation in the International Space Station.”
It’s successor, the Canadarm2, was mounted on the International Space Station in 2001, and has since been augmented with the addition of the Dextre robotic hand – also of Canadian design and manufacture. This arm, like its predecessor, has become a mainstay of operations aboard the ISS.
“Over the past 15 years, Canadarm2 has played a critical role in assembling and maintaining the Station,” said Eyssen. “It was used on almost every Station assembly mission. Canadarm2 and Dextre are used to capture commercial space ships, unload their cargo and operate with millimeter precision in space. They are both featured on our $5 bank notes. The technology behind these robots also benefits those on earth through technological spin-offs used for neurosurgery, pediatric surgery and breast-cancer detection.”
Canada’s Dextre robotic “handyman” and Canadarm2 pictured digging out the trunk of a SpaceX’s Dragon cargo vessel docked to the ISS. Credit: NASA
In terms of optics, the CSA is renowned for the creation of the Advanced Space Vision System (SVS) used aboard the ISS. This computer-vision system uses regular 2D cameras located in the Space Shuttle Bay, on the Canadarm, or on the hull of the ISS itself – along with cooperative targets – to calculate the 3D position of objects around of the station.
But arguably, Canada’s most enduring contribution to space exploration have come in the form of its astronauts. Long before Hadfield was garnering attention with his rousing rendition of David Bowie’s “Space Oddity“, or performing “Is Someone Singing (ISS)” with The Barenaked Ladies and The Wexford Gleeks choir (via a video connection from the ISS), Canadians were venturing into space as part of several NASA missions.
Consider Marc Garneau, a retired military officer and engineer who became the first Canadian astronaut to go into space, taking part in three flights aboard NASA Space shuttles in 1984, 1996 and 2000. Garneau also served as the president of the Canadian Space Agency from 2001 to 2006 before retiring for active service and beginning a career in politics.
And how about Roberta Bondar? As Canada’s first female astronaut, she had the additional honor of designated as the Payload Specialist for the first International Microgravity Laboratory Mission (IML-1) in 1992. Bondar also flew on the NASA Space Shuttle Discovery during Mission STS-42 in 1992, during which she performed experiments in the Spacelab.
The Soyuz TMA-15 crew (from left to right), showing Robert Thirsk, Roman Romanenko, and Frank De Winne. Credit: NASA/Victor Zelentsov
And then there’s Robert Thirsk, an engineer and physician who holds the Canadian records for the longest space flight (187 days 20 hours) and the most time spent in space (204 days 18 hours). All three individuals embodied the unique combination of academic proficiency, advanced training, personal achievement, and dedication that make up an astronaut.
And just like Hadfield, Bonard, Garneau and Thirsk have all retired on gone on to have distinguished careers as chancellors of academic institutions, politicians, philanthropists, noted authors and keynote speakers. All told, eight Canadians astronauts have taken part in sixteen space missions and been deeply involved in research and experiments conducted aboard the ISS.
Alas, every generation has to retire sooner or later. And having made their contributions and moved onto other paths, the CSA is looking for two particularly bright, young, highly-motivated and highly-skilled people to step up and take their place.
The recruitment campaign was announced this past Sunday, July 17th, by the Honourable Navdeep Bains – the Minister of Innovation, Science and Economic Development. Those who are selected will be based at NASA’s Johnson Space Center in Houston, Texas, where they will provide support for space missions in progress, and prepare for future missions.
Canadian astronaut Chris Hadfield, the first Canadian to serve as commander of the ISS. Credit: CTV
Canadian astronauts also periodically return to Canada to participate in various activities and encourage young Canadians to pursue an education in the STEM fields (science, technology, engineering and mathematics). As Eyssen explained, the goals of the recruitment drive is to maintain the best traditions of the Canadian space program as we move into the 21st century:
“The recruitment of new astronauts will allow Canada to maintain a robust astronaut corps and be ready to play a meaningful role in future human exploration initiatives. Canada is currently entitled to two long-duration astronaut flights to the ISS between now and 2024. The first one, scheduled for November 2018, will see David Saint-Jacqueslaunch to space for a six-month mission aboard the ISS. The second flight will launch before 2024. As nations work together to chart the next major international space exploration missions, our continued role in the ISS will ensure that Canada is well-positioned to be a trusted partner in humanity’s next steps in space.
“Canada is seeking astronauts to advance critical science and research aboard the International Space Station and pave the way for human missions beyond the Station. Our international partners are exploring options beyond the ISS. This new generation of astronauts will be part of Canada’s next chapter of space exploration. That may include future deep-space exploration missions.”
The recruitment drive will be open from June 17th to August 15th, 2016, and the selected candidates are expected to be announced by next summer. This next class of Canadian astronaut candidates will start their training in August 2017 at the Johnson Space Center. The details can be found at the Canadian Space Agency‘s website, and all potential applicants are advised to read the campaign information kit before applying.
Alongside their efforts to find the next generation of astronauts, the Canadian government’s 2016 annual budget has also provided the CSA with up to $379 million dollars over the next eight years to extend Canada’s participation in the International Space Station on through to 2024. Gotta’ keep reaching for those stars, eh?
Three newly arrived crew of Expedition 48 in Soyuz MS-01 open the hatch and enter the International Space Station after docking on July 9, 2016. Credit: NASA TV
Three newly arrived crew of Expedition 48 in Soyuz MS-01 open the hatch and enter the International Space Station after docking on July 9, 2016. Credit: NASA TV
A flawless shakedown mission from Russia’s newly modified Soyuz capsule successfully delivered a new multinational crew to the Space Station early Saturday, July 9 after a two day orbital chase.
The upgraded Soyuz MS-01 spacecraft launching on its maiden flight successfully docked to the International Space Station at 12:06 a.m. EDT Saturday, July 9, while soaring 254 statute miles over the South Pacific.
“Docking confirmed,” said a commentator from Russian mission control at Korolev outside Moscow. “Contact and capture complete.”
The Soyuz was ferrying the new multinational trio of astronauts and cosmonauts comprising Kate Rubins of NASA, Soyuz Commander Anatoly Ivanishin of the Russian space agency Roscosmos and Takuya Onishi of the Japan Aerospace Exploration Agency on the Expedition 48/49 mission.
The three person crew of two men and one woman had launched flawlessly into picture perfect skies two days earlier from the Baikonur Cosmodrome in Kazakhstan at 9:36 p.m. EDT Wednesday, July 6 (7:36 a.m. Baikonur time, July 7), in the brand new version of the Russian Soyuz capsule that has been significantly upgraded and modified.
NASA’s Kate Rubins was strapped into the right seat, Ivanishin in the center and Onishi on the left.
The Soyuz MS-01 spacecraft, carrying three Expedition 48-49 crew members, launches from the Baikonur Cosmodrome in Kazakhstan at 9:36 p.m. EDT Wednesday, July 6, 2016 (7:36 a.m. Baikonur time, July 7). Credits: NASA/Bill Ingalls
It was a textbook approach on the shakedown mission that culminated in a flawless docking at the Earth-facing Russian Rassvet module on the Russian side of the massive orbiting outpost.
NASA TV carried the whole operation live with beautiful color video imagery streaming from the ISS showing the Soyuz approach and black and white video streaming from the Soyuz.
The Soyuz MS-01 spacecraft is viewed from the International Space Station as it approaches the Rassvet module docking port. Credit: NASA TV
The Soyuz performed magnificently. All of the upgraded and modified systems checked out perfectly on this maiden flight of the new version of Russias venerable Soyuz, said NASA commentator Rob Navias.
“All new systems functioning perfectly,” said Navias. “This has been a perfect shakedown mission for the new Soyuz crew docking at the ISS.”
The Soyuz had slowed to an approach velocity of just 0.1 m/s at docking with the forward docking probe extended.
The approach was fully automated under Russian mission control as Ivanishin carefully monitored all spacecraft systems with steady update calls back to ground control.
The fully automated approached utilized the upgraded KURS NA automated rendezvous radar system.
During final approach, the Soyuz conducted a fly around maneuver starting at a distance of 400 meters. It moved 57 degress around the station while closing in to about 250 meters.
After station keeping for about 2 minutes while ground controllers conducted a final evaluation and no issues were detected, Russian mission control at last gave the GO for final approach and the GO command for docking was given.
The Soyuz made contact and completed a perfect docking at Rassvet. The hook and latches were then closed in for a tight grasp onto the station.
The crews then conducted a series of leak and pressurization checks.
After everything checked out, the hatches were finally opened about two and a half hours later at 2:26 a.m. EDT.
The new crew members of Expedition 48 officially floated aboard the International Space Station at about 2:50 a.m. EDT, July 9 with the hatches opened between their Soyuz MS-01 and the space station and after a live video transmission link had been established to show the festivities.
The new six-member Expedition 48 crew join each other for well wishes and congratulations from family, friends and mission officials. In front, from left, are the new crew members Kate Rubins, Anatoly Ivanishin and Takuya Onishi. In the back row are Flight Engineers Oleg Skripochka and Alexey Ovchinin and Commander Jeff Williams. Credit: NASA TV
They were welcomed aboard with hugs and joined the Expedition 48 Commander Jeff Williams of NASA and Flight Engineers Oleg Skripochka and Alexey Ovchinin of Roscosmos.
With the arrival of Rubins, Ivanishin and Onishi, the stations resident crew is beefed up to its normal six person crew complement.
They soon held the traditional video telecon for well wishes and congratulations from family, friends and mission officials.
The new trio will spend at least four months at the orbiting lab complex conducting more than 250 science investigations in fields such as biology, Earth science, human research, physical sciences, and technology development.
Rubins is on her rookie space mission. She holds a bachelor’s degree in molecular biology and a doctorate in cancer biology which will be a big focus of her space station research activities.
The new trio will join Expedition 48 Commander Jeff Williams of NASA and Flight Engineers Oleg Skripochka and Alexey Ovchinin of Roscosmos.
“The approximately 250 research investigations and technology demonstrations – not possible on Earth – will advance scientific knowledge of Earth, space, physical, and biological sciences. Science conducted on the space station continues to yield benefits for humanity and will enable future long-duration human and robotic exploration into deep space, including the agency’s Journey to Mars,” says NASA.
The newly upgraded Soyuz offers increased reliability and enhanced performance.
Many changes were instituted including enhanced structural performance to minimize chances of micrometeoroid penetration. Engineers also added a fifth battery for more power and storage capacity. The solar arrays are also about one square meter larger and the efficiency of the solar cells increased about 2 percent.
Also a more modern command and telemetry system to interact with a new series of new Russian communications satellites that will offer greatly increased the coverage by ground control. This was previously only about 20 minutes per orbit while over Russian ground stations and will now increase up to 45 to 90% of orbital coverage via the Russian comsat system.
A phased array antenna was also added with increased UHF radio capability in the Soyuz descent module that now also include a GPS system to improve search and rescue possibilities.
The newly upgraded KURS rendezvous radar system will weigh less, use less power and overall will be less complicated. For example it doesn’t have to be moved out of the way before docking. Weighs less and uses less power.
New approach and attitude control thrusters were installed. The new configuration uses 28 thrusters with a redundant thruster for each one – thus two fully redundant manifolds of 28 thrusters each.
All of these modification were tested out on the last two progress vehicles.
Multiple unmanned cargo ships carrying tons of essential supplies and science experiments are also scheduled to arrive from Russia, the US and Japan over the next few months.
A SpaceX Dragon is scheduled to launch as soon as July 18 and an Orbital ATK Cygnus should follow in August.
The SpaceX Dragon CRS-9 mission is slated to deliver the station’s first International docking adapter (IDA) to accommodate the future arrival of U.S. commercial crew spacecraft, including the Boeing built Starliner and SpaceX built Crew Dragon.
A Japanese HTV cargo craft will carry lithium ion batteries to replace the nickel-hydrogen batteries currently used on station to store electrical energy generated by the station’s huge rotating solar arrays.
Two Russian Progress craft with many tons of supplies are also scheduled to arrive.
The Soyuz MS-01 spacecraft launches from the Baikonur Cosmodrome with Expedition 48-49 crewmembers Kate Rubins of NASA, Anatoly Ivanishin of Roscosmos and Takuya Onishi of the Japan Aerospace Exploration Agency (JAXA) onboard, Thursday, July 7, 2016 , Kazakh time (July 6 Eastern time), Baikonur, Kazakhstan. Photo Credit: NASA/Bill Ingalls
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
The Soyuz MS-01 spacecraft launches from the Baikonur Cosmodrome with Expedition 48-49 crewmembers Kate Rubins of NASA, Anatoly Ivanishin of Roscosmos and Takuya Onishi of the Japan Aerospace Exploration Agency (JAXA) onboard, Thursday, July 7, 2016 , Kazakh time (July 6 Eastern time), Baikonur, Kazakhstan. Photo Credit: NASA/Bill Ingalls
The Soyuz MS-01 spacecraft launches from the Baikonur Cosmodrome with Expedition 48-49 crewmembers Kate Rubins of NASA, Anatoly Ivanishin of Roscosmos and Takuya Onishi of the Japan Aerospace Exploration Agency (JAXA) onboard, Thursday, July 7, 2016 , Kazakh time (July 6 Eastern time), Baikonur, Kazakhstan. Photo Credit: NASA/Bill Ingalls
An international trio of astronauts and cosmonauts representing the United States, Russia and Japan blasted off in the early morning Kazakh hours today, July 7, for a new mission of science and discovery on the International Space Station (ISS).
The three person crew of two men and one woman launched flawlessly into picture perfect skies from the Baikonur Cosmodrome in Kazakhstan at 9:36 p.m. EDT Wednesday, July 6 (7:36 a.m. Baikonur time, July 7), and in a brand new version of the Russian Soyuz capsule that has been significantly upgraded and modified.
The launch of the Soyuz MS-01 spacecraft was carried live on NASA TV starting approximately an hour before the usual on time liftoff from Baikonur. The three stage Soyuz booster generates 930,000 pounds of liftoff thrust.
The trio comprises Kate Rubins of NASA, Soyuz Commander Anatoly Ivanishin of the Russian space agency Roscosmos and Takuya Onishi of the Japan Aerospace Exploration Agency on the Expedition 48/49 mission.
They safely reached orbit at about 9:46 p.m. after the eight minute climb delivered them to the preliminary orbit of 143 x 118 mi. The Soyuz separated from the third stage and the solar arrays deployed as planned. NASA’s Kate Rubins was strapped into the left seat, Ivanishin in the center and Onishi on the right.
And precisely because it’s a heavily modified Soyuz, they will take the slow road to the ISS.
The crew will spend the next two days and 34 Earth orbits inside in order to fully check out and test the upgraded Soyuz spacecraft systems.
That’s in contrast to missions in recent years that took a vastly sped up 4 orbit 6 hour route to the space station.
International Space Station Expedition 48/49 astronaut Kate Rubins of NASA, Russian cosmonaut Anatoly Ivanishin and Japan Aerospace Exploration Agency (JAXA) astronaut Takuya Onishi. Credits: NASA
Three carefully choreographed orbital adjustment burns will raise the orbit and propel the crew to the ISS over the next 2 days.
They expect to rendezvous and dock at the space station’s Russian Rassvet module at 12:12 a.m. EDT Saturday, July 9. After conducting leak and safety check they expect to open the hatch to the ISS at about 2:50 a.m. Saturday, July 9.
You can watch all the hatch opening action live on NASA TV with coverage starting at 2:30 a.m.
They will spend about four months at the orbiting lab complex conducting more than 250 science investigations in fields such as biology, Earth science, human research, physical sciences, and technology development.
The Soyuz MS-01 spacecraft launches from the Baikonur Cosmodrome with Expedition 48-49 crewmembers Kate Rubins of NASA, Anatoly Ivanishin of Roscosmos and Takuya Onishi of the Japan Aerospace Exploration Agency (JAXA) onboard, Thursday, July 7, 2016 , Kazakh time (July 6 Eastern time), Baikonur, Kazakhstan. Rubins, Ivanishin, and Onishi will spend approximately four months on the orbital complex, returning to Earth in October. Photo Credit: (NASA/Bill Ingalls)
With the arrival of Rubins, Ivanishin and Onishi, the station is beefed up to its normal six person crew complement.
Rubins is on her rookie space mission. She holds a bachelor’s degree in molecular biology and a doctorate in cancer biology which will be a big focus of her space station research activities.
The new trio will join Expedition 48 Commander Jeff Williams of NASA and Flight Engineers Oleg Skripochka and Alexey Ovchinin of Roscosmos.
The Expedition 48 crew members will spend four months contributing to more than 250 experiments in fields such as biology, Earth science, human research, physical sciences and technology development.
“The approximately 250 research investigations and technology demonstrations – not possible on Earth – will advance scientific knowledge of Earth, space, physical, and biological sciences. Science conducted on the space station continues to yield benefits for humanity and will enable future long-duration human and robotic exploration into deep space, including the agency’s Journey to Mars,” says NASA.
The Soyuz MS-01 spacecraft service structure is put into place after the rocket rolled out by train to the launch pad at the Baikonur Cosmodrome, Kazakhstan, Monday, July 4, 2016. NASA astronaut Kate Rubins, cosmonaut Anatoly Ivanishin of the Russian space agency Roscosmos, and astronaut Takuya Onishi of the Japan Aerospace Exploration Agency (JAXA) will launch from the Baikonur Cosmodrome in Kazakhstan the morning of July 7, Kazakh time (July 6 Eastern time.) All three will spend approximately four months on the orbital complex, returning to Earth in October. Photo Credit: (NASA/Bill Ingalls)
The newly upgraded Soyuz offers increased reliability and enhanced performance. Many changes were instituted including enhanced structural performance to minimize chances of meteorite penetration. Engineers also added a fifth battery for more power and storage capacity. The solar arrays are also about one square meter larger and the efficiency of the solar cells increased about 2 percent.
Also a more modern command and telemetry system to interact with a new series of new Russian communications satellites that will offer greatly increased the coverage by ground control from only about 20 minutes per orbit up to from 45 to 90% of orbital coverage.
A phased array antenna was also added with increased UHF radio capability in the Soyuz descent module that now also include a GPS system to improve search and rescue possibilities.
The newly upgraded KURS rendezvous radar system will weigh less, use less power and overall will be less complicated. For example it doesn’t have to be moved out of the way before docking. Weighs less and uses less power.
New approach and attitude control thrusters were installed. The new configuration uses 28 thrusters with a redundant thruster for each one – thus two fully redundant manifolds of 28 thrusters each.
All of these modification were tested out on the last two progress vehicles.
Multiple unmanned cargo ships carrying tons of essential supplies and science experiments are also scheduled to arrive from Russia, the US and Japan over the next few months.
A SpaceX Dragon could launch as soon as July 18 and an Orbital ATK Cygnus could follow in August.
The Dragon CRS-9 mission is slated to deliver the station’s first International docking adapter (IDA) to accommodate the future arrival of U.S. commercial crew spacecraft, including the Boeing built Starliner and SpaceX built Crew Dragon.
A Japanese HTV cargo craft will carry lithium ion batteries to replace the nickel-hydrogen batteries currently used on station to store electrical energy generated by the station’s huge rotating solar arrays.
Two Russian Progress craft with many tons of supplies are also scheduled to arrive.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
